- DL manuals
- Taylor-Dunn
- Utility Vehicle
- B0-254-48
- Operation, T Roubleshooting And Replacement Parts Manual
Taylor-Dunn B0-254-48 Operation, T Roubleshooting And Replacement Parts Manual
Summary of B0-254-48
Page 1
T h e b e s t w a y to go a b o u t your b u s i n e s s ® serial number range: 165448 - 170871 revision: c equipped with gt-drive system gt drive models inlcuded: b0-254-48 (b 2-54) manual mb-254-02 operation, troubleshooting and replacement parts manual lavatory service vehicle.
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Taylor-dunn service center for more information about this and other taylor-dunn ® manuals, please write taylor-dunn ® : taylor-dunn ® mfg. 2114 w. Ball road anaheim, ca 92804 (attn: technical writer) copyright notice copyright © 2001 by taylor-dunn ® mfg. All rights reserved. No part of this work m...
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Table of contents t a y l or - dun n th e b e st w ay to go about yo ur bu si n e ss r a small sample of the many types of vehicles offered by taylor-dunn ® b 2-48-36 equipped with optional hydraulic dump bed bt 2-80 eight passenger tram b 1-00 personnel carrier c 4-25 huskey tow tractor mx 1600 equ...
Page 5: Contents
Table of contents contents introduction ............................................................ 1 about this manual ..................................................................... 2 who should read this manual ............................................... 3 responsibilities ...............
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Table of contents periodic maintenance checklist .............................................. 16 standard periodic maintenance schedule for the smart view display ................................................. 17 daily visual inspection .............................................................
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Table of contents brake service ......................................................... 1 inspect the service brake ........................................................ 2 disc brake pads ..............................................................................................................
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Table of contents transmission.......................................................... 1 check oil level ......................................................................... 2 change oil ................................................................................. 3 motor removal and inst...
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Table of contents sevcon control system troubleshooting ............ 1 test equipment required: ............................................................................................... 2 important notes and instructions ............................................................................
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Table of contents appendix a-special tools.................................... A-1 appendix b: standard hardware suggested torque limits ..................................................... 1 hardware identification ............................................................ 2 standard head markin...
Page 11: Introduction
Introduction about this manual ........................................ 2 who should read this manual ................... 3 responsibilities ............................................ 3 how to use this manual .............................. 4 conventions ...............................................
Page 12: About This Manual
Introduction introduction page-2 about this manual the purchase of this vehicle shows a belief in high quality products manufactured in the usa. Taylor-dunn ® , a leading manufacturer of electric burden and personnel carriers since 1949, wants to be sure this vehicle provides years of reliable servi...
Page 13: Who Should Read This Manual
Introduction introduction page-3 who should read this manual this manual is intended for use by anyone who is going to operate, own, perform maintenance on, service, or order parts for this taylor-dunn ® vehicle. Each person should be familiar with the parts of this manual that apply to their use of...
Page 14: How to Use This Manual
Introduction introduction page-4 how to use this manual this manual is organized into five main sections: introduction this section describes how to use this service manual and how to identify your vehicle. Safety rules and operating instructions this section outlines the safety and operational issu...
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Introduction introduction page-5 a shaded box with the word “warning” on its left denotes a warning. A warning alerts the reader of a hazard that may result in injury to themselves or others. Be sure to follow any instructions contained within a warning and exercise extreme care while performing the...
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Introduction introduction page-6 how to identify your vehicle this manual applies to vehicles with the same model and serial numbers listed on the front cover. These vehicles are designed for driving on smooth surfaces in and around facilities such as industrial plants, nurseries, institutions, mote...
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Introduction introduction page-7 taking delivery of your vehicle inspect the vehicle immediately after delivery. Use the following guidelines to help identify any obvious problems: • examine the contents of all packages and accessories that may have come in separate packages with the vehicle. • make...
Page 18: Taylor -Dunn
Taylor -dunn.
Page 19: Safety Rules and Operating
Table of contents standard specifications ............................... 2 safety rules and guidelines ........................ 3 driver training program ............................... 4 driver qualifications. ................................................. 4 key-switch ............................
Page 20: Standard Specifications
Safety rules and operating instructions safety rules page 2 standard specifications item voltage specification occupancy driver only electrical system 48 volt 6-165 amp hour, 8 volt, lead acid batteries, solid state speed control, 500 amp dimensions 467.36l x 149.86w x ?? H centimeters 184l x 59w x ...
Page 21
Safety rules page 3 safety rules and operating instructions 1. Make sure the key-switch is in the “off” position, then remove the key. 2. Place the forward-reverse switch in the center “off” position. 3. Set the park brake. 4. Place blocks under the front wheels to prevent vehicle movement. 5. Disco...
Page 22: Driver Training Program
Safety rules and operating instructions safety rules page 4 driver training program according to ansi b56.8, the owner of this vehicle shall conduct an operator training program for all those who will be operating this vehicle. The training program shall not be condensed for those claiming to have p...
Page 23: Vehicle Controls
Safety rules page 5 safety rules and operating instructions vehicle controls forward-off-reverse switch the forward-off-reverse switch, located on the right side of the instrument panel, determines the direction of travel of the vehicle. Push the top of the switch to engage the forward direction. Pu...
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Safety rules and operating instructions safety rules page 6 headlight switch the headlight switch is located on the top left of the instrument panel. Push the right side of the switch to turn the lights on. Push the left side of the switch to turn the light off. Accessory switch (optional) the acces...
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Safety rules page 7 safety rules and operating instructions smart view display the smart view display (svd) functions as a battery status indicator (bsi), hour meter (hm), speed controller status monitor, and as an optional maintenance monitor feature. The operation of each of these functions is lis...
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Safety rules and operating instructions safety rules page 8 run time hours: after the initial 5-seconds, the run time hours will be displayed as indicated by the run time hours indicator located at the left of the display. The icon represents a motor symbol with a “t” in the center. Run time hours i...
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Safety rules page 9 safety rules and operating instructions steering the steering wheel and steering system are similar to an automobile. To turn right, turn the steering wheel clockwise. To turn left, turn the steering wheel counter-clockwise. If equipped with tilt steering, the release lever is lo...
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Safety rules and operating instructions safety rules page 10 electrolyte alarm (optional) the electrolyte alarm is located in the battery area, in the 4th battery cell from the main battery positive cable. The electrolyte alarm is activated when the battery cell fluid level falls below the level of ...
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Safety rules page 11 safety rules and operating instructions vehicle operational guidelines safety guidelines • do not operate this vehicle while using any substance such as medication, drugs, or alcohol that may impair your judgment, reaction times, or driving ability. • only qualified and trained ...
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Safety rules and operating instructions safety rules page 12 while driving: • slow down and sound the horn to warn pedestrians or when approaching a corner or other intersection. • no reckless driving. • do not drive this vehicle on steep inclines or where prohibited. • immediately report any accide...
Page 31: Charging Your Vehicle
Safety rules page 13 safety rules and operating instructions charging your vehicle battery electrolyte is poisonous and dangerous. It contains sulfuric acid. Avoid contact with skin eyes or clothing. Wear rubber gloves and safety glasses while servicing batteries. Do not ingest! This may result in s...
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Safety rules and operating instructions safety rules page 14 to obtain the maximum battery life: charge the batteries only after they reach a normal discharge as indicated on the battery status indicator (bsi). Failure to follow this guideline could result in the batteries entering an overcharge sta...
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Safety rules page 15 safety rules and operating instructions storing and returning to service both storing your vehicle and returning it to service should only be performed by authorized personnel. Storing your vehicle • clean the batteries, then fill and charge before putting the vehicle in storage...
Page 34
Safety rules and operating instructions safety rules page 16 maintenance item 2, 3 weekly 1 (20hrs) monthly 1 (80hrs) quaterly 1 (250hrs) semi - annual 1 (500hrs) annualy 1 (1000hrs) check condition of tires and tire pressure l check all lights, horns, beepers and warning devises l check and fill ba...
Page 35: For The Smart View Display
Safety rules page 17 safety rules and operating instructions preventative maintenance schedule maintenance level hour interval 1 maintenance to be performed 2 1 500 inspect the brake system including the park brake and mounting harware inspect the steering system, tighten the steering shaft coupler ...
Page 36: Maintenance Guidelines For
Safety rules and operating instructions safety rules page 18 maintenance guidelines for severe duty applications 1. This maintenance checklist is based on the average application. If the vehicle is operated under “severe conditions”, service procedures should be conducted more frequently than specif...
Page 37: General Maintenance
Table of contents general maintenance maintenance guidelines ............................... 2 troubleshooting guide ................................. 3 lubrication chart .......................................... 4.
Page 38: Maintenance Guidelines
Maintenance, service and repair maintenance page 2 maintenance guidelines • avoid fire hazards and have fire protection equipment present in the work area. Conduct vehicle performance checks in an authorized area where safe clearance exists. • before starting the vehicle, follow the recommended safe...
Page 39: Troubleshooting Guide
Maintenance, service and repair maintenance page 3 troubleshooting guide symptom probable cause steering pulls in o ne direction front end out of alignment low tire pressure hard steering dry lube points in steering linkage damaged king p in/ball joint low tire pressure excessive steering play worn ...
Page 40: Lubrication Chart
Maintenance, service and repair maintenance page 4 lubrication chart # description locations lubricant type 1 ball joints 4 general purpose grease 2 pedal linkages 3 general purpose grease 3 front wheel bearings 2 high temperature wheel bearing grease 4 king pin 2 general purpose grease 7 drive drai...
Page 41: Front Axle Service
Table of contents inspect the front wheel bearings and king pin ........................................... 2 adjust front wheel bearings ....................... 3 front axle removal and installation ............ 4 removal ................................................................... 4 install...
Page 42
Maintenance, service, and repair front axle page 2 inspect the front wheel bearings and king pin 6. Raise the front of the vehicle and support with jack stands. 7. Grab the top and bottom of the tire/wheel assembly. Feel for any movement or play while pulling and pushing on the top and bottom of the...
Page 43
Maintenance, service, and repair front axle page 3 1. Make sure the key-switch is in the “off” position, then remove the key. 2. Place the forward-reverse switch in the center “off” position. 3. Set the park brake. 4. Place blocks under the rear wheels to prevent vehicle movement. 5. Disconnect the ...
Page 44
Maintenance, service, and repair front axle page 4 1. Make sure the key-switch is in the “off” position, then remove the key. 2. Place the forward-reverse switch in the center “off” position. 3. Set the park brake. 4. Place blocks under the rear wheels to prevent vehicle movement. 5. Disconnect the ...
Page 45
Maintenance, service, and repair front axle page 5 1. Make sure the key-switch is in the “off” position, then remove the key. 2. Place the forward-reverse switch in the center “off” position. 3. Set the park brake. 4. Place blocks under the rear wheels to prevent vehicle movement. 5. Disconnect the ...
Page 46: Front Axle Disassembly
Maintenance, service, and repair front axle page 6 front axle disassembly disassembling and reassembling involves removing and replacing the left and right steering knuckles and king pin bushings. Refer to the following sections for information regarding these procedures: replace the steering knuckl...
Page 47: Replace Front Wheel Bearings
Maintenance, service, and repair front axle page 7 1. Make sure the key-switch is in the “off” position, then remove the key. 2. Place the forward-reverse switch in the center “off” position. 3. Set the park brake. 4. Place blocks under the rear wheels to prevent vehicle movement. 5. Disconnect the ...
Page 48
Maintenance, service, and repair front axle page 8 13. Install the hub dust cap. 14. Reinstall the brake body and the tire/wheel assembly. Note: refer to the brakes section for information regarding the installation of the brake body. 15. Lower the vehicle. 16. Reconnect the main positive and negati...
Page 49
Maintenance, service, and repair front axle page 9 replace the king pins and bushings there are different types of king pin bushings depending on the configuration of your vehicle. • bronze bushings in the axle beam. • bronze bushings in the steering knuckle. • metal backed teflon bushings in the ax...
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Maintenance, service, and repair front axle page 10 failure to correctly broach or ream bronze bushings may result in steering difficulty and loss of control of the vehicle causing severe bodily injury and/or property damage. 7. Remove the steering knuckle. Refer to replace the steering knuckle for ...
Page 51: Replace The Steering Knuckle
Maintenance, service, and repair front axle page 11 1. Make sure the key-switch is in the “off” position, then remove the key. 2. Place the forward-reverse switch in the center “off” position. 3. Set the park brake. 4. Place blocks under the rear wheels to prevent vehicle movement. 5. Disconnect the...
Page 52
Maintenance, service, and repair front axle page 12 12. Thoroughly clean and/or replace all bearings, nuts, washers, and bushings. Note: both the left and right side bushings and thrust bearings should be replaced as a set. 13. Assemble in reverse order. 14. Pack the thrust bearing with grease. 15. ...
Page 53: Steering Component Service
Table of contents steering component service front end alignment ..................................... 2 inspect ball joints ......................................... 6 inspect rod ends .......................................... 7 adjust the steering gear ............................... 8 replace th...
Page 54: Front End Alignment
Maintenance, service, and repair steering page 2 front end alignment this section will refer to two different types of ball joints. One type is has a grease fitting and a tapered shaft where it is fitted to the steering arm or pitman arm. The second type cannot be greased and has a straight shaft. S...
Page 55
Maintenance, service, and repair steering page 3 10. At this point both the steering wheel and the front wheels should be tied up and held in position. If one or the other is not tied up then you must start from the beginning. 11. Loosen the ball joint clamps or the rod end jam nuts on the drag link...
Page 56
Maintenance, service, and repair steering page 4 1. Make sure the key-switch is in the “off” position, then remove the key. 2. Place the forward-reverse switch in the center “off” position. 3. Set the park brake. 4. Place blocks under the rear wheels to prevent vehicle movement. 5. Disconnect the ma...
Page 57
Maintenance, service, and repair steering page 5 rotate the steering wheel from a full left turn to a full right turn and make sure that the ball joint clamps do not contact any other component. Clamps positioned so that they contact other components may result in steering failure and loss of contro...
Page 58: Inspect Ball Joints
Maintenance, service, and repair steering page 6 1. Make sure the key-switch is in the “off” position, then remove the key. 2. Place the forward-reverse switch in the center “off” position. 3. Set the park brake. 4. Place blocks under the rear wheels to prevent vehicle movement. 5. Disconnect the ma...
Page 59: Inspect Rod Ends
Maintenance, service, and repair steering page 7 inspect rod ends note: a set of ball joints and/or rod ends will wear at the same rate. If a ball joint and or rod end is worn out, then all should be replaced as a set. 6. Visually inspect each rod end for any signs of play between the ball and the n...
Page 60: Adjust The Steering Gear
Maintenance, service, and repair steering page 8 1. Make sure the key-switch is in the “off” position, then remove the key. 2. Place the forward-reverse switch in the center “off” position. 3. Set the park brake. 4. Place blocks under the rear wheels to prevent vehicle movement. 5. Disconnect the ma...
Page 61
Maintenance, service, and repair steering page 9 13. While rotating the input shaft back and forth through its centered position, adjust the gear lash adjusting screw so that there is a slight drag as the steering gear is rotated through its centered position. 14. While holding the gear lash adjusti...
Page 62: Replace The Steering Shaft
Maintenance, service, and repair steering page 10 1. Make sure the key-switch is in the “off” position, then remove the key. 2. Place the forward-reverse switch in the center “off” position. 3. Set the park brake. 4. Place blocks under the front wheels to prevent vehicle movement. 5. Disconnect the ...
Page 63
Maintenance, service, and repair steering page 11 do not use the original pinch bolt and nut. Failure to replace the pinch bolt and nut may result in failure of the steering causing loss of control of the vehicle. This could lead to property damage and/or severe bodily injury. Make sure that the pin...
Page 64: Replace The Steering Wheel
Maintenance, service, and repair steering page 12 1. Make sure the key-switch is in the “off” position, then remove the key. 2. Place the forward-reverse switch in the center “off” position. 3. Set the park brake. 4. Place blocks under the front wheels to prevent vehicle movement. 5. Disconnect the ...
Page 65: Replace The Steering Gear
Maintenance, service, and repair steering page 13 1. Make sure the key-switch is in the “off” position, then remove the key. 2. Place the forward-reverse switch in the center “off” position. 3. Set the park brake. 4. Place blocks under the rear wheels to prevent vehicle movement. 5. Disconnect the m...
Page 66
Maintenance, service, and repair steering page 14 replace the ball joints, tie rods, and drag link this section will refer to two different types of ball joints. One type is has a grease fitting and a tapered shaft where it is installed on the steering arm or pitman arm. The second cannot be greased...
Page 67
Maintenance, service, and repair steering page 15 10. Install the new rod end into the steering sleeve. Screw it into the sleeve the same number of turns counted in the previous step. Do not tighten the rod end clamp or jam nut at this time. 11. Install the rod end into the steering arm. Tighten the...
Page 68
Maintenance, service, and repair steering page 16 12. Install the ball joint into the steering arm. Tighten the ball joint nut to 40-45 ft-lbs. And install a new cotter pin. 13. Realign the front wheels. Note: refer to the steering section for information regarding realignment of the front wheels. 1...
Page 69
Maintenance, service, and repair steering page 17 11. Lower the vehicle. 12. Reconnect the main positive and negative cables at the batteries. 13. Remove the blocks from behind the wheels. 14. Release the park brake and test drive the vehicle. Replacing the tie rod the tie rod is the linkage that co...
Page 70: Center The Steering Gear
Maintenance, service, and repair steering page 18 center the steering gear 1. Remove the pitman arm. 2. Rotate the input shaft clockwise until it stops. 3. While counting the rotations, rotate the input shaft counter clockwise until it stops. 4. Rotate the input shaft clockwise 1/2 the rotations cou...
Page 71: Repair The Steering Gear
Maintenance, service, and repair steering page 19 repair the steering gear disassembly note: the steering gear must be removed from the vehicle for this procedure. Refer to replace the steering gear section for information regarding removing the steering gear. Note: the steering gear is packed with ...
Page 72
Maintenance, service, and repair steering page 20 4. Remove the worm shaft and ball nut assembly from the bottom of the housing. 5. Remove the worm shaft seal. 6. Remove the pitman shaft seal. 7. Remove the upper worm bearing and bearing cup from the housing. 8. The ball nut assembly consists of two...
Page 73
Maintenance, service, and repair steering page 21 9. Place the upper worm bearing on the worm shaft and install the worm shaft/ball nut assembly into the housing being careful not to damage the worm shaft seal. 10. Install the assembled worm bearing adjuster into the housing and tighten just enough ...
Page 74
Maintenance, service, and repair steering page 22 exploded view of steering gear.
Page 75: Brake Service
Table of contents inspect the service brake ............................. 2 disc brake pads ...................................................... 2 disc brake rotor ..................................................... 3 inspect the parking brake ............................. 4 wheel park brake (hy...
Page 76: Inspect The Service Brake
Maintenance, service, and repair brakes page 2 disc brake pads note: the brake pad must be removed to accurately measure the lining thickness. Refer to replace the front or rear brake pads section for information on removing the brake pads. Measure the brake pad lining at the thinnest point on the p...
Page 77
Maintenance, service, and repair brakes page 3 rotor removed for clarity. The rotor does not have to be removed for this procedure. Do not use a rotor that is worn beyond its service limits. A rotor worn beyond its service limits could fail and cause loss of brakes resulting in severe bodily injury ...
Page 78: Inspect The Parking Brake
Maintenance, service, and repair brakes page 4 inspect the parking brake wheel park brake (hydraulic disc) note: the parking brake is actuated through a pin in the center of the rear left and right brake body on the rear axles. 6. Release the park brake. 7. Inspect the brake pads. Refer to inspect t...
Page 79
Maintenance, service, and repair brakes page 5 electric motor brake a variable power supply capable of supplying 0-volts to 24-volts dc at 2-amps will be required to perform the testing. The brake does not have to be removed from the transmission for this test. 6. Disconnect the electric brake conne...
Page 80: Adjust The Service Brakes
Maintenance, service, and repair brakes page 6 adjust the service brakes two or four wheel hydraulic disc brakes the hydraulic disc brake system is automatically adjusted. A low brake pedal or lack of braking power could be caused by: • brake fluid level low in the master cylinder. See check the mas...
Page 81: Adjust The Parking Brake
Maintenance, service, and repair brakes page 7 adjust the parking brake wheel park brake (hydraulic disc) the parking brake is actuated through a pin in the center of the rear left and right brake body on the rear axles. 1. Make sure the key-switch is in the “off” position, then remove the key. 2. P...
Page 82: Check Master Cylinder Fluid
Maintenance, service, and repair brakes page 8 check master cylinder fluid 6. Thoroughly clean the area around the master cylinder cap. 7. Remove the master cylinder cap. 8. If the fluid in the master cylinder is contaminated then the entire brake system must be flushed. Refer to bleed the brakes fo...
Page 83: Bleed The Brake System
Maintenance, service, and repair brakes page 9 bleed the brake system note: start this procedure at the wheel furthest from the master cylinder, then work toward the wheel closest to the master cylinder. 6. Thoroughly clean the area around the master cylinder cap and remove the cap. Do not ingest br...
Page 84
Maintenance, service, and repair brakes page 10 7. Add brake fluid from a new sealed container to the master cylinder. Fill to 1/4” from the top of the master cylinder chamber. 8. The master cylinder fluid level will drop as the brakes are bled. Periodically check and fill the master cylinder during...
Page 85: Flush The Brake System
Maintenance, service, and repair brakes page 11 flush the brake system 1. Make sure the key-switch is in the “off” position, then remove the key. 2. Place the forward-reverse switch in the center “off” position. 3. Set the park brake. 4. Place blocks under the front wheels to prevent vehicle movemen...
Page 86: (Electric Motor Brake)
Maintenance, service, and repair brakes page 12 current taylor-dunn ® brakes are asbestos free. However, there is the possibility that the original brakes were replaced with aftermarket parts containing asbestos. Since this possibility exists, all brake parts should be handled as if they contain asb...
Page 87
Maintenance, service, and repair brakes page 13 6. Mark the orientation of the inner contact plate in relation to the magnet. 7. Remove the smaller bearing circlip. 8. Using a soft hammer, drive out the center hub and remove the inner contact plate and six springs. 9. If required, remove the larger ...
Page 88
Maintenance, service, and repair brakes page 14 electric motor brake exploded inspection: note: there are no repairable parts in this assembly. The parts must be replaced if any damage or wear is found. 1. Measure the free length of the five springs. Minimum length =0.713” 2. Inspect the splines on ...
Page 89
Maintenance, service, and repair brakes page 15 replace front disc brake pads note: it is recommended that both the left and right brake pads be replaced as a set. 1. Make sure the key-switch is in the “off” position, then remove the key. 2. Place the forward-reverse switch in the center “off” posit...
Page 90
Maintenance, service, and repair brakes page 16 note: refer to the illustration above for the following steps. 10. Remove the brake body bolts (10) and discard the lock nuts (1) and brake pads (8). 11. Remove the spacer bushings (6) from the mounting bracket (5) and discard the bushings. 12. Inspect...
Page 91: Replace Rear Brake Pads
Maintenance, service, and repair brakes page 17 1. Make sure the key-switch is in the “off” position, then remove the key. 2. Place the forward-reverse switch in the center “off” position. 3. Set the park brake. 4. Place blocks under the front wheels to prevent vehicle movement. 5. Disconnect the ma...
Page 92
Maintenance, service, and repair brakes page 18 9. Remove the tire/wheel assembly. Note: refer to tires and wheels section for information on removing the tire and wheel assembly. 10. Release the park brake (wheel brake only). 11. Remove the brake body bolts and discard the lock nuts and brake pads....
Page 93: Replace The Wheel Cylinder
Maintenance, service, and repair brakes page 19 1. Make sure the key-switch is in the “off” position, then remove the key. 2. Place the forward-reverse switch in the center “off” position. 3. Set the park brake. 4. Place blocks under the wheels to prevent vehicle movement. 5. Disconnect the main pos...
Page 94
Maintenance, service, and repair brakes page 20 8. Remove the tire/wheel assembly. Refer to tires and wheels section for information on removing the tire and wheel assembly. 9. Thoroughly clean the area around the brake body. 10. Remove the brake body bolts and discard the lock nuts. 11. Inspect the...
Page 95: Repair The Brake Body
Maintenance, service, and repair brakes page 21 1. Make sure the key-switch is in the “off” position, then remove the key. 2. Place the forward-reverse switch in the center “off” position. 3. Set the park brake. 4. Place blocks under the front wheels to prevent vehicle movement. 5. Disconnect the ma...
Page 96
Maintenance, service, and repair brakes page 22 11. Lubricate the brake parts with clean brake fluid from a sealed container. 12. Install the o-rings into the brake body. Make sure that the o-rings are installed into the second groove and that they are not twisted. 13. Using tool #41-350-13, slide t...
Page 97: Replace The Master Cylinder
Maintenance, service, and repair brakes page 23 replace the master cylinder note: most vehicle configurations do not require lifting the vehicle to remove the master cylinder. Lifting the vehicle may not be required. 6. If required, raise the vehicle and support with jack stands. 7. Place a drain pa...
Page 98
Maintenance, service, and repair brakes page 24 10. Install in reverse order. 11. Adjust the master cylinder push rod so that it is approximately 1/8 inch away from the master cylinder plunger when the brake pedal is up. 12. Fill the master cylinder with brake fluid from a sealed container. 13. Pump...
Page 99: Repair The Master Cylinder
Maintenance, service, and repair brakes page 25 repair the master cylinder note: hydraulic brake system components must be kept clean. Make sure your work area is free from dirt and debris and will contain any brake fluid spills. Remove the master cylinder from the vehicle. See replace the master cy...
Page 100: Taylor -Dunn
Taylor -dunn.
Page 101: Motor Service
Table of contents inspecting the motor brushes ...................... 2 motors with internal cooling fans ............................... 2 motor removal and installation ................... 3 motor inspection ........................................... 3 replacing the brushes or armature bearing .....
Page 102: Inspecting The Motor Brushes
Motor service motor page 2 inspecting the motor brushes motors with internal cooling fans note: there are four brushes in the motor. The brushes will not wear at the same rate. It is recommended that all four brushes are inspected at the same time. Note: in some vehicle configurations it may not be ...
Page 103: Motor Inspection
Motor service motor page 3 inspection 1. Measure the length of each motor brush. • if any one brush is less than or equal to the service limit specified in section service limits , then all four brushes should be replaced. Refer to replacing the brushes section for information regarding replacing th...
Page 104
Motor service motor page 4 insulation commutator incorrect hacksaw blade correct min. Od armature undercut typical burn mark on a shorted armature 2. Measure the diameter of the commutator. • if the commutator is less than the minimum diameter specified in section service limits , then the motor mus...
Page 105
Motor service motor page 5 check each segment all of the way around the commutator hold this lead in place commutator 7. Visually inspect the armature windings for burnt insulation. Burnt insulation is a direct result of motor overheating and could lead to a shorted armature. • if the insulation is ...
Page 106
Motor service motor page 6 assembly 1. Press a new bearing into the motor housing and install the circlip. 2. Install the two brush assemblies so that the brushes are just far enough out of the brush holder so that the brush springs hold them in place away from the commutator. See the illustration t...
Page 107
Motor service motor page 7 replacing the brushes or armature bearing note: it is recommended that all four brushes be replaced as a set. Note: the motor must be disassembled to replace the brushes or the bearing. Refer to motor inspection-disassembly section for information on taking the motor apart...
Page 108: Repairing The Commutator
Motor service motor page 8 example of freshly cut commutator properly undercut and cleaned commutator segments repairing the commutator 1. The motor must be removed from the vehicle for this procedure. Refer to transmission service section for information on removing the motor. 2. The armature must ...
Page 109
Motor service motor page 9 insulation commutator incorrect hacksaw blade correct min. Od armature undercut example of freshly cut commutator undercutting the commutator 1. Using a small straight cut saw blade, cut the commutator insulation to the proper depth. Refer to undercut depth in service limi...
Page 110: Service Limits
Motor service motor page 10 service limits motor specification number undercut depth commutator diameter (min) brush length (min) resistance (ohms@75º f) mm inches mm inches mm inches armature field 70-054-40 (xp-1672 or dv1-4002) 0.635 0.025 69.85 2.75 15.87 0.625 .0116 1.20 70-054-41 (xp-1789 or d...
Page 111: Transmission
Table of contents gt transmission assembly with disc brakes transmission check oil level ............................................. 2 change oil ..................................................... 3 motor removal and installation .................... 4 rear hub or rotor ...........................
Page 112: Check Oil Level
Maintenance, service, and repair transmission page 2 check oil level the oil flows freely between the main gear case (3rd member) and the primary reduction gear case. It is only necessary to check the oil level of the 3rd member. Park the vehicle on a level surface. 6. Place a level on the top of th...
Page 113: Change Oil
Maintenance, service, and repair transmission page 3 change oil 6. Raise the rear of the vehicle and support with jack stands. 7. Place a four quart drain pan under the drive assembly. 8. Remove the drain plugs from the differential case and gear case. 9. Once the oil has drained, replace the drain ...
Page 114
Maintenance, service, and repair transmission page 4 motor removal and installation note: some applications will require removing the drive assembly from the vehicle to remove the motor. Refer to removing and installing the drive assembly for information on removing the drive assembly. Some vehicles...
Page 115: Rear Hub Or Rotor
Maintenance, service, and repair transmission page 5 rear hub or rotor note: the torque specification for the axle hub bolt is 275 ft-lbs. An impact wrench will be required to remove the bolt. Note: the axle hub bolt has a special thread locking compound applied to the threads. If this bolt is remov...
Page 116: (Disc Brakes)
Maintenance, service, and repair transmission page 6 removing and installing the rear axles (disc brakes) the oil level in the housing is above the bottom of the axle flange. To minimize oil spills, raise the side of the vehicle high enough so that the oil level is below the bottom of the axle flang...
Page 117
Maintenance, service, and repair transmission page 7 11. Remove the axle retaining plate and brake body assembly as one unit. 12. Secure the brake body assembly, do not let it hang by the brake hose. 13. Pull the axle out of the housing. 14. Inspect all bearings for roughness or play, replace as nee...
Page 118: Transmission Assembly
Maintenance, service, and repair transmission page 8 transmission assembly 1. Make sure the key-switch is in the “off” position, then remove the key. 2. Place the forward-reverse switch in the center “off” position. 3. Set the park brake. 4. Place blocks under the front wheels to prevent vehicle mov...
Page 119: Reduction Gear Case
Maintenance, service, and repair transmission page 9 disassembly and reassembly of the primary reduction gear case 6. Raise the rear of the vehicle and support with jack stands. Always use a lifting strap, hoist, and jack stands, of adequate capacity to lift and support the vehicle. Failure to use l...
Page 120
Maintenance, service, and repair transmission page 10 12. Remove the circlip from the idler gear. 13. Remove the input shaft/bearing assembly and idler gear/ bearing assembly from the gear case cover at the same time. 14. Remove the pinion nut from the output gear and remove the output gear from the...
Page 121
Maintenance, service, and repair transmission page 11 19. Assemble the gear case in reverse order. Note: torque the drain plug to 21-25 foot-pounds. Note: torque the gear case to 3rd member retaining bolts to 18-20 foot- pounds. Note: torque the pinion nut to 154-169 foot-pounds. Note: apply gasket ...
Page 122: Disassembling The 3Rd Member
Maintenance, service, and repair transmission page 12 disassembling the 3rd member 1. Make sure the key-switch is in the “off” position, then remove the key. 2. Place the forward-reverse switch in the center “off” position. 3. Set the park brake. 4. Place blocks under the front wheels to prevent veh...
Page 123
Maintenance, service, and repair transmission page 13 13. Remove the carrier bearing adjusting nut roll pin and adjusting nut from the side plate. 14. Turn the side plate over and remove the carrier bearing race from the side plate. 15. Remove the differential assembly from the 3rd member housing. 1...
Page 124
Maintenance, service, and repair transmission page 14 17. Remove the carrier bearing race from the 3rd member housing. 18. Remove the front bearing from the input shaft. Note: the input shaft may have to be driven out to perform this procedure. 19. Remove the input shaft’s shims and spacer. 20. Remo...
Page 125: Assembling The 3Rd Member
Maintenance, service, and repair transmission page 15 assembling the 3rd member 1. Temporarily install the pinion gear (hand tighten only). 2. Install the carrier bearing race ring nuts into the housing and cover. 3. Install the carrier bearing races into the housing and cover. Cover housing cover h...
Page 126
Maintenance, service, and repair transmission page 16 10. Mark the position of each carrier bearing ring nut in relation to the drive housing and cover and then remove the differential assembly, do not allow the ring nuts to rotate. 11. Install the pinion gear. Re-shim if required. 12. Install the p...
Page 127
Maintenance, service, and repair transmission page 17 17. Install the locking roll pins into the housing and cover to lock the ring nuts in place. 18. Remove the pinion gear holding tool. 19. Install the primary reduction gear case, axles and housings, motor, and install the complete drive onto the ...
Page 128
Maintenance, service, and repair transmission page 18 pinion bearing preload note: the pinion gear depth must be set before the preload. Refer to setting the pinion gear depth . 1. Install the pinion gear, spacer, and shims into the housing. 2. Install the outer pinion bearing. 3. Install the main g...
Page 129
Maintenance, service, and repair transmission page 19 pinion gear shimming instructions note: this procedure is required only when replacing the front or rear pinion bearings and races or the ring and pinion gears. Note: to perform this procedure, all parts must be clean and the bearings lightly lub...
Page 130
Maintenance, service, and repair transmission page 20 note: values shown are for reference only c d.
Page 131: Suspension
Table of contents suspension replace the rear springs ............................. 2 replace the front springs ............................ 3 replace the spring bushings ....................... 4 replace the shocks ...................................... 5.
Page 132: Replace The Rear Springs
Maintenance, service, and repair suspension page 2 replace the rear springs 1. Make sure the key-switch is in the “off” position, then remove the key. 2. Place the forward-reverse switch in the center “off” position. 3. Set the park brake. 4. Place blocks under the front wheels to prevent vehicle mo...
Page 133: Replace The Front Springs
Maintenance, service, and repair suspension page 3 damaged or worn spring bolts or hangers could result in sudden failure of the suspension causing severe bodily injury or property damage. 1. Make sure the key-switch is in the “off” position, then remove the key. 2. Place the forward-reverse switch ...
Page 134: Replace The Spring Bushings
Maintenance, service, and repair suspension page 4 replace the spring bushings it is recommended that all front spring bushings are replaced as a set. Your vehicle will be equipped with one of two types of spring bushings, internal and external (see illustration to the right): • the internal bushing...
Page 135: Replace The Shocks
Maintenance, service, and repair suspension page 5 replace the shocks it is recommended to replace all shocks as a set. Note: on some vehicles it may be required to remove the front wheel to gain access to the shock mounting bolts. Refer to tires and wheels section for information regarding removing...
Page 136: Taylor -Dunn
Taylor -dunn.
Page 137: Tires and Wheels
Table of contents tire inflation .................................................. 2 tire inspection .............................................. 2 replace the tire/wheel ................................. 3 repair the tire (pneumatic) ......................... 4 replace the tire (pneumatic) ........
Page 138: Tire Inflation
Maintenance, service, and repair tires and wheels page 2 tire inflation 1. Make sure the key-switch is in the “off” position, then remove the key. 2. Place the forward-reverse switch in the center “off” position. 3. Set the park brake. 4. Place blocks under the front wheels to prevent vehicle moveme...
Page 139: Replace The Tire/wheel
Maintenance, service, and repair tires and wheels page 3 8. Inspect for uneven tire wear on the front tires. Uneven tire wear could be a result of an improperly inflated tire or a misaligned or damaged front end. Note: refer to tire inflation section or steering component service section for informa...
Page 140
Maintenance, service, and repair tires and wheels page 4 pattern for tightening the wheel nuts do not attempt to repair a tire with a damaged side wall or a slice in the tread. This type of repair could fail prematurely resulting in severe bodily injury and/or property damage. Re-torque all wheel nu...
Page 141
Maintenance, service, and repair tires and wheels page 5 explosion hazard. Fully deflate the tire before attempting to remove the tire from the wheel. Do not over inflate the tire when seating the bead. Failure to deflate the tire or over inflating the tire to seat the bead may cause explosive failu...
Page 142: Taylor -Dunn
Taylor -dunn.
Page 143: Battery Service
Table of contents cleaning ........................................................ 2 testing ........................................................... 3 watering ........................................................ 5 charging ........................................................ 6 replacin...
Page 144: Cleaning
Maintenance, service, and repair batteries page 2 cleaning battery electrolyte will stain and corrode most surfaces. Immediately and thoroughly clean any surface outside of the battery that the battery electrolyte comes in contact with. Failure to clean may result in property damage. 1. Make sure th...
Page 145: Testing
Maintenance, service, and repair batteries page 3 testing note: a combination of the load test and specific gravity test should be used to accurately determine the condition of the batteries. Load test (6-volt batteries only) note: the batteries must be fully charged before performing this test. 1. ...
Page 146
Maintenance, service, and repair batteries page 4 typical hydrometer float specific gravity test note: the batteries must be fully charged before performing this test. The specific gravity of a cell is an indication of the actual state of charge of the cell. A fully charged cell should have a readin...
Page 147: Watering
Maintenance, service, and repair batteries page 5 watering note: the electrolyte level in a battery rises while charging and will be close to its highest level after the end of a charging cycle. It is recommended to fill the batteries at the end of a charging cycle. If the electrolyte is below the t...
Page 148: Charging
Maintenance, service, and repair batteries page 6 1. Make sure the key-switch is in the “off” position, then remove the key. 2. Place the forward-reverse switch in the center “off” position. 3. Set the park brake. 4. Place blocks under the front wheels to prevent vehicle movement. 5. Disconnect the ...
Page 149
Maintenance, service, and repair batteries page 7 battery electrolyte will stain and corrode most surfaces. Immediately and thoroughly clean any surface outside of the battery that the battery electrolyte comes in contact with. Failure to clean may result in property damage. 1. Make sure the key-swi...
Page 150
Maintenance, service, and repair batteries page 8 do not leave cables on batteries that have been removed from the vehicle. Cables left on batteries could cause a short circuit resulting in battery explosion, severe bodily injury and/or property damage. When torquing battery hardware, use a backup w...
Page 151
Maintenance, service, and repair batteries page 9 1. Make sure the key-switch is in the “off” position, then remove the key. 2. Place the forward-reverse switch in the center “off” position. 3. Set the park brake. 4. Place blocks under the front wheels to prevent vehicle movement. 5. Disconnect the ...
Page 152
Maintenance, service, and repair batteries page 10 if the batteries are removed from the vehicle, do not place them directly on the ground, concrete or solid metal surface. It is recommended to store them on a wooden pallet or equivalent. Storing on the ground, concrete or solid metal surface will c...
Page 153
Maintenance, service, and repair batteries page 11 1. Make sure the key-switch is in the “off” position, then remove the key. 2. Place the forward-reverse switch in the center “off” position. 3. Set the park brake. 4. Place blocks under the front wheels to prevent vehicle movement. 5. Disconnect the...
Page 154: Taylor -Dunn
Taylor -dunn.
Page 155
Sevcon control system troubleshooting this troubleshooting guide is written in sequential order. All tests must be performed in the order that they are written. Starting in the middle or skipping sections when not instructed to do so may lead to invalid test results. Table of contents test equipment...
Page 156
Sevcon troubleshooting page 2 electrical troubleshooting test equipment required: • digital multimeter (dmm) with diode test function, fluke 79 model shown. • throttle module analyzer, taylor-dunn part number 62-027-32 definitions: • battery volts = full voltage available at the batteries at the tim...
Page 157
Sevcon troubleshooting page 3 electrical troubleshooting identifying your controller.
Page 158
Sevcon troubleshooting page 4 electrical troubleshooting if your vehicles is equipped with an electric motor brake, the motor brake system must be checked to be sure it is working properly before continuing with this troubleshooting. Operating the speed control when the motor brake has not disengage...
Page 159
Sevcon troubleshooting page 5 electrical troubleshooting test 1. Checking the control logic inputs close the seat switch. Place the high/low switch in the high position. Connect a voltmeter across the iso solenoid coil terminals and carefully monitor the voltage as the key switch is turned on. Turn ...
Page 160
Sevcon troubleshooting page 6 electrical troubleshooting test 1.5: test the voltage at pin #4 on the 12-pin logic card connector. If the voltage is high, then skip ahead to test #1.6. If the voltage is low, then skip ahead to test #6. Test 1.6: test the voltage at pin #7 on the 12-pin logic card con...
Page 161
Sevcon troubleshooting page 7 electrical troubleshooting test 2. Testing the motor disconnect both of the battery leads during any maintenance or before disconnecting any electrical component or wire. Failure to do so may cause property damage and/or serious bodily injury. Note: special and expensiv...
Page 162
Sevcon troubleshooting page 8 electrical troubleshooting test 2.4: reaching this point indicates an open circuit in the motor wiring. Check the continuity of all wires from the controller to the motor. Repair any open wires then test drive the vehicle. Stop trouble shooting here and repair the probl...
Page 163
Sevcon troubleshooting page 9 electrical troubleshooting test 3. The vehicle runs in one direction only test 3.5 disconnect the batteries and remove wires from the b-, f1, and f2 terminals on the controller. Using the diode test function on your meter, connect the positive lead to the b- terminal on...
Page 164
Sevcon troubleshooting page 10 electrical troubleshooting test 4. Key fault test 4.3: test the voltage at the cold side (violet/black wire) of the key switch. If the voltage equals battery volts, then skip ahead to test #4.4. If the voltage does not equal battery volts, then replace the key switch. ...
Page 165
Sevcon troubleshooting page 11 electrical troubleshooting test 5. Contactor coil fault disconnect the 12-pin logic card connector from the sevcon power unit. Turn the key switch on and perform the following tests: test 5.1: check the voltage on the positive coil terminal of the iso solenoid (violet ...
Page 166
Sevcon troubleshooting page 12 electrical troubleshooting test 6. Accelerator module fault with the power switch off, connect the throttle module to the analyzer. Position the power switch to the 0-5 volt range. All but the power lamp should be off. If the fs-1, fs-3 or ov lamp (over voltage) are on...
Page 167
Sevcon troubleshooting page 13 electrical troubleshooting test 7. Forward and reverse switch fault turn the key switch on, place the forward and reverse switch in the center off position and perform the following tests: test 7.1: referencing battery positive, test the voltage on the center terminal ...
Page 168
Sevcon troubleshooting page 14 electrical troubleshooting test 7.3: if the vehicle does not travel in forward, skip ahead to test #7.4. Place the forward and reverse switch in the reverse position. Referencing battery positive, test the voltage at the white/black wire on the f&r switch. If the volta...
Page 169
Sevcon troubleshooting page 15 electrical troubleshooting test 8. Anti-rolloff fault the sevcon controller is equipped with a feature called anti-rolloff. Anti-rolloff will automatically slow the vehicle if it starts to roll. Anti-rolloff is active when the key switch has been left in the “on” posit...
Page 170
Sevcon troubleshooting page 16 electrical troubleshooting test 9. Electric motor brake description: the electric motor brake is a 24-volt electromagnetic disc brake mounted between the drive motor and the primary reduction gear case. The brake is controlled by the speed controller logic. At what tim...
Page 171
Sevcon troubleshooting page 17 electrical troubleshooting connect a volt meter across the violet/black wire at the electric brake harness plug and pin #9 at the logic card connector. The voltage should start at approximately 24 volts, then drop to approximately 15 volts after about 0.5 seconds. If t...
Page 172
Sevcon troubleshooting page 18 electrical troubleshooting pin# condition volts* 1 key switch off 0.0 volts key switch on battery volts 2 f&r in forward low f&r in neutral high f&r in reverse 3 f&r in reverse low f&r in neutral high f&r in forward 4 accelerator pedal up high accelerator pedal down lo...
Page 173
Sevcon troubleshooting page 19 electrical troubleshooting status led code table the status led on the sevcon power unit logic card can be used to give you an idea of where the problem may be. It is recommended that you complete the troubleshooting procedure to confirm failure of any component. Numbe...
Page 174
Sevcon troubleshooting page 20 electrical troubleshooting smart view fault codes level 5 faults (f05xxx) f05000 “contactor over current” this faut occurs when too much current is going into the line contactor coil circuit. This could be a result of a shorted contactor coil, short in the wiring, or f...
Page 175
Sevcon troubleshooting page 21 electrical troubleshooting level 2 faults (f02xxx) f02000: “accelerator” wiring to throttle module is open or faulty throttle module. F02001: “accelerator (power up)” throttle module fs-1 switch is closed (pedal depressed) or wiring shorted when start switch is turned ...
Page 176: Taylor -Dunn
Taylor -dunn.
Page 177: Lestronic II
Table of contents lestronic ii ® charger troubleshooting operating instructions and theory of operation .........................2 testing the charging cycle ....................3 test equipment required for troubleshooting ..............................4 important notes and instructions -----------...
Page 178
Electrical troubleshooting charger troubleshooting page 2 operating instructions and theory of operation the lestronic ii ® chargers are designed as semiautomatic chargers. The lestronic ii ® charger turns itself on when the “built- in” charger is plugged into the wall outlet, or when the “portable”...
Page 179: Testing The Charging Cycle
Electrical troubleshooting charger troubleshooting page 3 testing the charging cycle in typical installations, the charger will remain on for up to 12 hours depending on the state of charge of the battery when the charge cycle was started. A charger could remain on for longer than 12 hours if: • the...
Page 180
Electrical troubleshooting charger troubleshooting page 4 test equipment required for troubleshooting digital multi meter (dmm) with diode and capacitor test function, fluke 79 ® model shown at right and in the troubleshooting illustrations. Important notes and instructions • this troubleshooting gu...
Page 181
Electrical troubleshooting charger troubleshooting page 5 troubleshooting for built-in charger 5. Disconnect the charger from the ac source. Locate the charger harness connectors where the charger harness is connected to the vehicle’s control harness. There will be two 10 gauge and two 14 gauge wire...
Page 182
Electrical troubleshooting charger troubleshooting page 6 • disconnect the charger from the ac source. • disconnect the batteries. • disconnect the charger from the vehicle’s harness. • remove the charger from the vehicle. Remove the charger cover and perform the following tests: 1. Inspect the inte...
Page 183
Electrical troubleshooting charger troubleshooting page 7 • test the voltage from the fuse assembly (-) to the diode block (+). This voltage should be equal to the battery voltage. If the voltage is less than the battery voltage, then the wires from the harness connectors to the charger are bad . St...
Page 184
Electrical troubleshooting charger troubleshooting page 8 troubleshooting for portable charger disconnect the charger from the ac outlet and the batteries. 1. Test the voltage from the positive terminal on the vehicles dc receptacle to main battery negative. This voltage should be equal to the batte...
Page 185: Testing The Timer Relay
Electrical troubleshooting charger troubleshooting page 9 5. Reconnect the lead to the diode. 6. Connect the charger to the ac source. Insert the dc charger plug into the dc receptacle and perform the following tests: • test the voltage from the fuse assembly (-) to the diode block (+). This voltage...
Page 186: Testing The Interlock Relay
Electrical troubleshooting charger troubleshooting page 10 testing the interlock relay operation the interlock relay disables the vehicle from running whenever the charger is connected to a working ac power source. When the charger is plugged in, the relay contacts open and break the key switch conn...
Page 187
Table of contents ® operating instructions and theory of operation ........................................2 hb/pt and gel indicator lamps ...........3 testing the charging cycle ....................3 test equipment required for troubleshooting ...............................4 important notes and in...
Page 188
Electrical troubleshooting signet charger troubleshooting page 2 operating instructions and theory of operation the model hb600w ® and hb1000w ® chargers are designed as semiautomatic chargers. The charger turns itself on when it is plugged into the wall outlet and turns off when the batteries are f...
Page 189: Testing The Charging Cycle
Electrical troubleshooting signet charger troubleshooting page 3 testing the charging cycle in typical installations, the charger will remain on for up to 12 hours depending on the state of charge of the batteries when the charge cycle was started. Note: charging time is limited to 18-hours (max). A...
Page 190
Electrical troubleshooting signet charger troubleshooting page 4 test equipment required for troubleshooting digital multi meter (dmm), fluke 79 ® model shown at right and in the troubleshooting illustrations. Clamp on dc ammeter to measure up to 20-amps. Important notes and instructions • this trou...
Page 191: Status Led Error Code Table
Electrical troubleshooting signet charger troubleshooting page 5 status led error code table there are three status lights (led’s) on the charger name plate. These led’s normally indicate the current operating state of the charger. If all three led’s are flashing, it indicate an error has occurred i...
Page 192: Troubleshooting
Electrical troubleshooting signet charger troubleshooting page 6 1. Make sure the key-switch is in the “off” position, then remove the key. 2. Place the forward-reverse switch in the center “off” position. 3. Set the park brake. 4. Place blocks under the front wheels to prevent vehicle movement. Tro...
Page 193: Illustrated Parts
Table of contents steering knuckle ......................................... 2 front brakes ............................................... 4 steering linkage ......................................... 6 steering column ......................................... 8 steering gear ..........................
Page 194: Steering Knuckle
Illustrated parts parts page 2 steering knuckle.
Page 195
Illustrated parts parts page 3 steering knuckle item # part # description qty 1 15-210-70 axle beam 1 - - 4 88-239-86 3/4-nf hex nylon lock nut 2 5 88-228-60 3/4 cut flat washer 2 6 98-603-07 rubber bushing 2 7 01-220-99 washer 2 8 32-240-44 bushing 2 9 32-240-43 bushing 2 10 80-309-12 thrust bearin...
Page 196: Front Brakes
Illustrated parts parts page 4 front brakes brake body (#9 above).
Page 197
Illustrated parts parts page 5 front brake item # part # description qty 1 88-067-21 bolt, 1/4 x 3-3/4" nc, hex head, gr. 8 4 2 41-350-51 plate, secondary, hydraulic disc 2 3 41-348-70 pad, disc brake 4 4 41-348-57 spacer, disc brake 4 5 32-240-41 bearing teflon r coated 4 6 99-588-00 bleeder screw ...
Page 198: Steering Linkage
Illustrated parts parts page 6 steering linkage.
Page 199
Illustrated parts parts page 7 steering linkage item # part # description qty 1 18-057-00 tie rod 1 2 86-510-00 ball joing clamp 4 3 86-501-98 ball joing (left) 2 4 86-501-99 ball joint (right) 2 5 88-527-11 1/8 x 1 cotter pin 4 6 k1-157-99 drag link 1 7 88-159-85 1/2nf castle nut 4 - 18-104-00 pitm...
Page 200: Steering Column
Illustrated parts parts page 8 steering column ref., steering gear 8 9 the steering column is an integral part of the frame and is not shown. Part id# 5 is located in the top of the steering column tube. 7 4 3 6 { 5 2 1.
Page 201
Illustrated parts parts page 9 steering column item # part # description qty 1 88-199-82 5/8nf hex nut 1 2 19-011-20 steering wheel 1 3 88-081-14 5/16nf x 1-1/2 hex bolt, grade 8 1 4 88-089-84 5/16nf hex lock nut, grade c 1 5 32-248-10 upper bushing 1 6 20-031-65 steering shaft assembly (incl. 3 and...
Page 202: Steering Gear
Illustrated parts parts page 10 steering gear 4 1 6 8 7 5 9 10 2 3 14 17 12 11 13 15 16 exploded steering gear.Dwg.
Page 203
Illustrated parts parts page 11 steering gear 18-308-21 item # part # description qty 1 18-308-70 locknut 1 2 18-308-71 adjuster assembly 1 3 18-308-72 worm assenbly 1 4 18-308-23 upper worm bearing 1 5 18-308-22 upper worm bearing race 1 6 18-308-77 housing 1 7 18-308-78 seal, pitman shaft 1 8 18-3...
Page 204: Front Suspension
Illustrated parts parts page 12 front suspension 1 2 3 4 7 8 front axle (ref) 5 wheels and tires illustration not available.
Page 205
Illustrated parts parts page 13 front suspension item # part # description qty 1 96-121-00 u-bolt 4 2 85-486-00 leaf spring 2 3 32-214-50 bushing 12 4 96-240-00 1/2nc x 4 hex bolt 6 5 88-149-81 1/2nc lock nut 8 6 - - - 7 88-149-81 1/2nc lock nut 6 8 16-872-00 spring hanger 4 wheels and tires item # ...
Page 206: Transmission Gear Case
Illustrated parts parts page 14 transmission gear case.
Page 207
Illustrated parts parts page 15 transmission gear case item # part # description qty 1 gt-71682 m8 x 60 bolt 12 2 gt-3287563 gear case cover 1 3 gt-71259 bearing 1 4 gt-3287533 input shaft, 18:1 1 5 gt-71982 o-ring 1 6 gt-3287503 eccentric shaft 1 7 gt-72005 bearing 2 8 gt-3287493 idler gear 1 9 gt-...
Page 208: Rear Axle
Illustrated parts parts page 16 transmission differential case rear axle inner bearing on optional double bearing axle does not have an oil seal or o-ring. Orientation of bearing should have o-ring groove adjacent to o-ring on outer bearing. Axle shaft inner bearing (no o-ring) outer bearing o-ring ...
Page 209
Illustrated parts parts page 17 transmission differential case item # part # description qty 9 gt-70302 m10 x 30 bolt 12 13 gt-3287183 ring and pinion gear set 1 14 gt-3297193 differential case cover 1 15 gt-3287133 adjusting ring 2 16 gt-70417 fill/level plug 1 17 gt-3287113 differential housing 1 ...
Page 210: Rear Brakes
Illustrated parts parts page 18 rear brakes brake body (#8 above).
Page 211
Illustrated parts parts page 19 rear brakes item # part # description qty 1 88-067-21 hex bolt, grade 8 4 2 41-350-51 secondary plate 2 3 41-348-70 brake pad 4 4 41-348-57 spacer 4 5 32-240-41 bushing 4 6 41-350-28 mounting bracket 2 7 see rear axle hex bolt with thread locking compund 8 8 - brake b...
Page 212: Master Cylinder
Illustrated parts parts page 20 master cylinder brake linkage linkage at the brake caliper.
Page 213
Illustrated parts parts page 21 dual reservoir master cylinder item # part # description qty 1 88-080-14 bolt, 5/16" x 1-1/2" nc, hex head 2 2 99-511-20 master cylinder (includes item #3) 1 3 99-511-52 cap seal, master cylinder 1 99-511-53 cap, master cylinder 1 4 88-088-61 washer, 5/16" 4 5 88-089-...
Page 214: Brake Lines
Illustrated parts parts page 22 brake lines.
Page 215
Illustrated parts parts page 23 brake lines with dual reservoir master cylinder item# part # description qty 1 99-648-54 brake line, front 1 2 k54-700-01 brake line, rear 1 3 99-648-57 brake line, front right 1 4 99-648-56 brake line, rear, 1 5 99-604-57 brake line, rear right, 1 6 99-604-56 brake l...
Page 216: Rear Suspension
Illustrated parts parts page 24 rear suspension view from rear.
Page 217
Illustrated parts parts page 25 rear suspension item # part # description qty not shown 96-240-00 1/2nc x 4 spring bolt (front of the leaf spring) 2 32-214-50 spring bushing (front of the leaf spring) 4 14 85-510-17 leaf spring 2 15 16-861-40 spring mounting plate (left) 1 16-861-41 spring mounting ...
Page 218: Motor
Illustrated parts parts page 26 motor rear motor mount.
Page 219
Illustrated parts parts page 27 motor 70-057-40 (dv1-4003) item # part # description qty 1 70-421-10 front housing 1 2 70-400-10 armature 1 3 70-209-40 field assembly 1 4 85-403-00 brush spring 4 5 70-173-00 brush holder 1 6 70-170-10 brush 8 7 70-417-00 bearing retainer 1 8 80-212-00 bearing 1 9 70...
Page 220: Instrument Panel (Dash)
Illustrated parts parts page 28 instrument panel (dash).
Page 221
Illustrated parts parts page 29 instrument panel item # part # description qty 1 71-100-00 aux. Switch opt 2 71-039-11 spst rocker switch 1 or 2 3 88-817-07 sheet metal screw 8 5 01-200-09 dash console, no cab 1 6 74-010-00 smart view display (see information below) 1 7 94-304-14 dash 1 8 71-039-02 ...
Page 222: Speed Control Panel
Illustrated parts parts page 30 speed control panel components located under the driver seat cushion 2 5 11 9 8 13 6 4 11 1 14 12 7.
Page 223
Illustrated parts parts page 31 speed control panel item # part # description qty 1 62-400-15* speed controller, 500 amp 2 k54-300-01 mounting panel 1 3 73-004-20 horn 1 4 79-844-20 main circuit breaker 1 5 71-300-02 line contactor 1 71-300-01 mounting bracket 1 6 88-838-06 #14 x 1/2 sheet metal scr...
Page 224: Miscellaneous Electrical
Illustrated parts parts page 32 miscellaneous electrical seat interlock switch accelerator module 10 14 13 11 12 seat frame 1b 1a motion alarms miscellaneous wire harness clamps 2 3 17 16 15 18 4.
Page 225
Illustrated parts parts page 33 miscellaneous electrical item # part # description qty not shown 75-152-82 chassie control harness 1 75-152-13 control panel harness 1 k54-300-00 power harness 1 75-152-83 dash harness 1 98-599-15 plastic grommet for 1.75 hole 98-599-20 plastic grommet for 2.5 hole 75...
Page 226: Signet® Charger
Illustrated parts parts page 34 signet® charger note: the harness connectors are not included with the charger. When replacing the charger order 2 each of the following: part # description 75-318-20 butt splice 75-320-51 knife connector.
Page 227
Illustrated parts parts page 35 signet® charger item # part # description qty 79-309-40 charger, 48 volt * replacement cover with ac cord and gasket 79-851-10 ammeter 1 k7-145-29 ac cord 1 k4-081-78 ac receptacle 1 note: ther are no user serviceable components inside the charger. * - not available a...
Page 228: Batteries
Illustrated parts parts page 36 batteries roll out battery box 7 8 1 1b neg pos neg pos neg pos neg pos neg pos neg pos 12 volt negative tap main positive main negative 1a 2.
Page 229
Illustrated parts parts page 37 batteries item # part # description qty 1a 75-237-00 battery jumper, 9" long 4 1b k1-153-99 battery jumper, 18" long 1 2 77-052-00 battery, 8-volt, 165ah 6 3 4 5 6 88-069-81 1/2nc nylon lock nut * 7 88-081-12 5/16nc x 1 hex bolt, stainless steel * 8 88-089-80 5/16nc h...
Page 230: Lighting
Illustrated parts parts page 38 lighting head and tail lights item # part # description qty k4l-000-00 headlight (includes 2 headlights) 1 72-022-00 tail light 1 or 2 72-022-51 tail ligh rubber grommet 1 or 2 72-022-52 tail light pigtail illustration not available seat cushions seat cushions item # ...
Page 231: Miscellaneous
Illustrated parts parts page 39 miscellaneous item # part # description qty 98-200-00 braked pedal pad 1 71-040-95 compartment lock 1 01-110-20 accelerator pedal 1 miscellaneous illustration not available.
Page 232: Taylor -Dunn
Taylor -dunn.
Page 233: Appendix A-Special Tools
Appendix a-special tools.
Page 234: Special Tools
Appendix a page 2 special tools special tools description purpose part number pinion seal installation tool used to install the pinion seal on all chain drive trucks with the band style brake or the speed sensor on the chain case cover. 43-201-50 chain case centering tool used to center the chain ca...
Page 235: Appendix B:
Table of contents appendix b: standard hardware suggested torque limits hardware identification ................................. 2 standard head markings ......................................... 2 hex bolts .................................................................. 2 other bolts .............
Page 236: Hardware Identification
Appendix b appendix b page-2 hardware identification standard head markings s.A.E. Grade 2 s.A.E. Grade 5 truss head, grade 2 carriage bolt, grade 2 (unless marked as above) other bolts note: torque value used should be for lowest grade of hardware used. If a grade 2 nut is used on a grade 8 bolt, u...
Page 237
Appendix b appendix b page-3 hex nuts s.A.E. Grade 5 s.A.E. Grade 8 hex lock nuts (stover) c or, or, b or, or, nuts with no markings are to be treated as s.A.E. Grade 2 lock nuts use a letter to indicate the grade of the nut. Grade a’ locknuts would be the equivelent of grade ‘2’ hex nuts, grade ‘b’...
Page 238: Suggested Torque Values
Appendix b appendix b page-4 diameter and tpi grade 2 tightening torque (ft-lb) grade 5 tightening torque (ft-lb) grade 8 tightening torque (ft-lb) l'9 tightening torque (ft-lb) 1/4-20 4-7 7-10 10-14 11 1/4-28 5-8 8-12 11-16 12 5/16-18 9-14 14-21 20-29 22 5/16-24 10-15 15-23 22-33 25 3/8-16 16-24 25...
Page 239: Suggested Torque Values
Appendix b appendix b page-5 suggested torque values (critical hardware) torque table torque range group description ft-lbs in-lbs nm brakes - - - - - - - - - - - - - - - - - - - - - - - - brake bolt (disc brake body) 11 - 11 132 - 132 15 - 15 brake line tube nut fittings 12 - 13 144 - 156 16.3 - 17...
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Appendix b appendix b page-6 t a y l or - du n n t h e b e st w ay to go about yo ur b u si n e s s r a small sample of the many types of vehicles offered by taylor-dunn ® b 2-48-36 equipped with optional hydraulic dump bed bt 2-80 eight passenger tram b 1-00 personnel carrier c 4-25 huskey tow trac...
Page 241: Appendix C
Appendix c brake lining handling precautions taylor-dunn does not currently supply asbestos fiber-brake pads/shoes with any vehicle. However, there is the possibility that the original brake pads/shoes were replaced with aftermarket pads/shoes containing asbestos. Since this possibility does exist, ...
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Model b 1-00
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Taylor-dunn ® mfg. 2114 w. Ball rd. Anaheim, ca 92804 (800)-688-8680 (714) 956-4040 (fax) (714) 956-0504 mailing address: p.O. Box 4240 anaheim, california 92803 visit our website: www.Taylor-dunn.Com.